Aerosol-generating article with integral heating element

ABSTRACT

There is provided an aerosol-generating article including a tobacco plug, a mouthpiece positioned downstream of the tobacco plug, and a resistive heating element positioned within the tobacco plug. The resistive heating element includes an upstream portion protruding from an upstream end of the tobacco plug, wherein the upstream portion of the resistive heating element includes at least two heater electrical contacts configured to receive a supply of electrical energy from at least two device electrical contacts when the aerosol-generating article including the resistive heating element is inserted into an aerosol-generating device.

The present invention relates to an aerosol-generating article having anintegrated heating element. The present invention also relates to anelectrically heated aerosol-generating system comprising anaerosol-generating article having an integrated heating element, and tomethods of manufacturing tobacco plugs and aerosol-generating articleseach having an integrated heating element.

One type of aerosol-generating system is an electrically operatedsmoking system. Known handheld electrically operated smoking systemstypically comprise an aerosol-generating device comprising a battery,control electronics and an electric heater for heating a smoking articledesigned specifically for use with the aerosol-generating device. Insome examples, the smoking article comprises a plug of anaerosol-forming substrate, such as a tobacco plug, and the heatercontained within the aerosol-generating device is inserted into theaerosol-forming substrate when the smoking article is inserted into theaerosol-generating device. However, the electric heater may becomecontaminated with material from the aerosol-forming substrate during useand cleaning the electric heater inside the device can be difficult. Insome cases, it may be necessary to dispose of the entire device if theheater cannot be adequately cleaned. Sometimes removal of the smokingarticle from the device is also difficult, which may result in the needfor a dedicated extraction tool to facilitate removal of the smokingarticle from the device without damaging the heater.

Accordingly, it would be desirable to produce an aerosol-generatingarticle and an electrically heated aerosol-generating system thataddress the issue of heater contamination and the difficulty inextracting the article from an aerosol-generating device.

According to a first aspect of the present invention there is providedan aerosol-generating article comprising a tobacco plug, a mouthpiecepositioned downstream of the tobacco plug, and a resistive heatingelement positioned within the tobacco plug. The resistive heatingelement comprises an upstream portion protruding from an upstream end ofthe tobacco plug, wherein the upstream portion of the resistive heatingelement comprises at least two heater electrical contacts for receivinga supply of electrical energy from at least two device electricalcontacts when the aerosol-generating article comprising the resistiveheating element is inserted into an aerosol-generating device.

As used herein, the term “aerosol-generating article” refers to anarticle comprising a tobacco plug that, when heated, releases volatilecompounds that can form an aerosol.

As used herein, the term “aerosol-generating device” refers to a devicethat interacts with an aerosol-generating article to generate anaerosol. The aerosol-generative device includes a supply of electricalenergy to operate the resistive heating element within theaerosol-generating article.

As used herein, the terms “upstream” and “downstream” are used todescribe the relative positions of components, or portions ofcomponents, of aerosol-generating articles according to the inventionwith respect to the direction of airflow through the aerosol-generatingarticle when a user draws on the aerosol-generating article. Inparticular, when a user draws on the article, air flows in thedownstream direction from the upstream end to the downstream end.

By providing a resistive heating element as part of theaerosol-generating article, rather than part of an aerosol-generatingdevice, the present invention addresses at least some of the issuesassociated with known electrically heated aerosol-generating systems. Inparticular, providing the aerosol-generating article with an integratedresistive heating element eliminates the need to remove contaminationfrom a heating element contained within an aerosol-generating device, asis the case with known electrically heated aerosol-generating systems inwhich the heater is a reusable heater fixed within an aerosol-generatingdevice. Providing the resistive heating element in theaerosol-generating article can also make it easier to remove the articlefrom an aerosol-generating device when compared to known electricallyheated aerosol-generating systems in which a fixed heating elementwithin the device can make it difficult to remove the article withoutthe use of a dedicated extraction tool.

In some embodiments, the resistive heating element may comprise anelectrically resistive heating track provided on an elongateelectrically insulating substrate, and wherein the electricallyresistive heating track is electrically connected to the at least twoheater electrical contacts. Providing an electrically resistive heatingtrack on an electrically insulating substrate can simplify themanufacture of the aerosol-generating article by facilitating separatemanufacture of the resistive heating element, which can then be insertedinto the tobacco plug after the remainder of the aerosol-generatingarticle has been constructed.

The resistive heating element may be provided to a consumer separatelyfrom the remainder of the aerosol-generating article so that theconsumer can insert the resistive heating element into the tobacco plug.This arrangement is particularly useful in embodiments in which theresistive heating element is reusable with a plurality ofaerosol-generating articles. Alternatively, a resistive heating elementmay be inserted into each tobacco plug during the manufacture of theaerosol-generating articles.

To facilitate the insertion of the resistive heating element into thetobacco plug, the elongate electrically insulating substrate ispreferably shaped in the form of one of a rod, a needle, a pin, a blade,or a cone. Additionally, or alternatively, the elongate electricallyinsulating substrate may comprise one or more serrated edges, whereinthe serrations are shaped to favour insertion of the resistive heatingelement into the tobacco plug and resist removal of the resistiveheating element from the tobacco plug. Providing such serrated edges canadvantageously prevent the resistive heating element from becomingdislodged from the tobacco plug when the aerosol-generating article isremoved from an aerosol-generating device.

In alternative embodiments, the elongate electrically insulatingsubstrate may have a helical shape so that the resistive heating elementcan be screwed into and out of the tobacco plug but cannot be pusheddirectly into or pulled directly out of the tobacco plug. Utilising ahelical shape can therefore prevent the resistive heating element frombecoming dislodged from the tobacco plug when the aerosol-generatingarticle is removed from an aerosol-generating device.

In those embodiments in which a resistive heating element is insertedinto each tobacco plug during the manufacture of aerosol-generatingarticles according to the present invention, the resistive heatingelement is typically disposable with the remainder of theaerosol-generating article. In such embodiments, the resistive heatingelement is preferably constructed from low-cost materials, such as lowcost metals and metal alloys.

Alternatively, the resistive heating element may be reusable withmultiple aerosol-generating articles. For example, a pack ofaerosol-generating articles may be provided with a single resistiveheating element, wherein the resistive heating element is removed fromthe tobacco plug of each aerosol-generating article after it has beensmoked and inserted into the next aerosol-generating article. In suchembodiments, it may be cost-effective to manufacture the resistiveheating element from more expensive materials. For example, reusableresistive heating elements may comprise an elongate electricallyinsulating substrate formed from a non-conductive ceramic.

Preferably, the electrically insulating substrate is operable at aworking temperature of up to about 700 degrees Celsius, more preferablyabout 800 degrees Celsius. Additionally, or alternatively, the operatingtemperature of the resistive heating element during use may be about 250degrees Celsius, more preferably about 300 degrees Celsius.

Suitable materials for forming the electrically resistive heating trackinclude but are not limited to: semiconductors such as doped ceramics,electrically “conductive” ceramics (such as, for example, molybdenumdisilicide), carbon, graphite, metals, metal alloys and compositematerials made of a ceramic material and a metallic material. Suchcomposite materials may comprise doped or undoped ceramics. Examples ofsuitable doped ceramics include doped silicon carbides. Examples ofsuitable metals include titanium, zirconium, tantalum and metals fromthe platinum group. Examples of suitable metal alloys include stainlesssteel, nickel-, cobalt-, chromium-, aluminium- titanium- zirconium-,hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-,manganese- and iron-containing alloys, and super-alloys based on nickel,iron, cobalt, stainless steel, Timetal® and iron-manganese-aluminiumbased alloys.

In some embodiments, the electrically resistive heating track comprisesone or more stamped portions of electrically resistive material, such asstainless steel. Alternatively, the electrically resistive heating trackmay comprise a heating wire or filament, for example a Ni—Cr(Nickel-Chromium), platinum, tungsten or alloy wire.

In any of those embodiments in which the resistive heating elementcomprises an electrically resistive heating track provided on anelongate electrically insulating substrate, the upstream portion of theresistive heating element may comprises a disc of electricallyinsulating material, wherein the disc comprises a downstream faceabutting an upstream end of the tobacco plug, wherein the elongateelectrically insulating substrate extends downstream from the downstreamface of the disc, and wherein the disc further comprises an upstreamface on which the at least two heater electrical contacts are provided.

Providing the resistive heating element with a disc of electricallyinsulating material at its upstream end advantageously facilitatesinsertion of the resistive heating element into the tobacco plug inthose embodiments in which the resistive heating element is insertedinto the tobacco plug after the tobacco plug has been formed.Specifically, the elongate electrically insulating substrate can besized so that when the resistive heating element is inserted into thetobacco plug so that the downstream face of the disc of electricallyinsulating material abuts the upstream end of the tobacco plug theelongate electrically insulating substrate, and therefore the resistiveheating track, are correctly positioned within the tobacco plug.

Advantageously, the upstream face of the disc of electrically insulatingmaterial also provides a large surface area on which the at least twoheater electrical contacts can be provided, which facilitates themanufacture of the resistive heating element.

The disc of electrically insulating material may be formed from the sameinsulating material as the elongate electrically insulating substrate,or they may be formed from different materials.

Preferably, the disc of electrically insulating material and theelongate electrically insulating substrate are formed from the samematerial. To simplify the manufacture of the resistive heating element,the disc of electrically insulating material and the elongateelectrically insulating substrate are preferably integrally formed froma single piece of electrically insulating material. For example, theresistive heating element may formed by moulding or otherwise casting anelectrically insulating material around the electrically resistiveheating track.

In any of those embodiments in which the resistive heating elementcomprises a disc of electrically insulating material, the disc and thetobacco plug preferably both have a substantially circularcross-sectional shape, wherein the diameter of the disc is substantiallythe same as the diameter of the tobacco plug. This advantageouslyfacilitates correct insertion of the resistive heating element into thetobacco plug. For example, in those embodiments in which a resistiveheating element is inserted into each tobacco plug during themanufacture of the aerosol-generating articles, a tubular guide may beused to ensure that the disc of electrically insulating material ispositioned coaxially with the tobacco plug.

In any of the embodiments described above, the aerosol-generatingarticle preferably further comprises an article securing elementconfigured to interact with a device securing element on anaerosol-generating device to releasably retain the aerosol-generatingarticle within the aerosol-generating device. By releasably retainingthe aerosol-generating article within the aerosol-generating device thearticle securing element can advantageously ensure that a reliableelectrical contact is maintained between the heater electrical contactsand corresponding device electrical contacts in the aerosol-generatingdevice during heating of the aerosol-generating article.

The article securing element is preferably configured so that forcesexerted on the aerosol-generating article during normal use of anelectrically heated aerosol-generating system comprising theaerosol-generating article inserted into an aerosol-generating deviceare insufficient to break the electrical contact between the heaterelectrical contacts and device electrical contacts, while also beingconfigured so that a consumer can easily remove the aerosol-generatingarticle, including the resistive heating element, from theaerosol-generating device. For example, the resistive heater element maycomprise a magnetised material provided at an upstream end of theresistive heater element, wherein the magnetised material interacts witha magnetised material or a non-magnetised but ferromagnetic materialprovided within the aerosol-generating device. In a particularlypreferred embodiment, at least one of the heater electrical contactscomprises a magnetised material, wherein the at least one heaterelectrical contact comprising a magnetised material is magneticallyattracted to the corresponding at least one device electrical contact toreleasably retain the heater electrical contacts in electrical contactwith the corresponding device electrical contacts when theaerosol-generating article is inserted into the aerosol-generatingdevice. In such embodiments, the article securing element comprises theat least one heater electrical contact comprising a magnetised material.The one or more device electrical contacts corresponding to the at leastone heater electrical contact comprising a magnetised material may alsocomprise a magnetised material. Alternatively, the one or more deviceelectrical contacts corresponding to the at least one heater electricalcontact comprising a magnetised material may comprise a non-magnetisedbut ferromagnetic material.

In an alternative embodiment, at least one of the device electricalcontacts comprises a magnetised material, wherein the at least onedevice electrical contact comprising a magnetised material ismagnetically attracted to the corresponding at least one heaterelectrical contact to releasably retain the heater electrical contactsin electrical contact with the corresponding device electrical contactswhen the aerosol-generating article is inserted into theaerosol-generating device. In such embodiments, the device securingelement comprises the at least one device electrical contact comprisinga magnetised material and the article securing element comprises the oneor more corresponding heater electrical contacts. The one or more heaterelectrical contacts corresponding to the at least one device electricalcontact comprising a magnetised material may also comprise a magnetisedmaterial. Alternatively, the one or more heater electrical contactscorresponding to the at least one device electrical contact comprising amagnetised material may comprise a non-magnetised but ferromagneticmaterial.

In further alternative embodiments, the article and device securingelements may interact mechanically to retain the aerosol-generatingarticle within the aerosol-generating device. For example, theaerosol-generating device may comprise a tapered cavity into which theaerosol-generating article is received, the tapered cavity providing aninterference fit between the tapered surface of the cavity and the outersurface of the aerosol-generating article. In such embodiments, thecavity forms the device securing element and the outer surface of theaerosol-generating article forms the article securing element.Alternatively, a different mechanical interaction may be providedbetween the aerosol-generating article and the aerosol-generatingdevice. For example, the aerosol-generating article may comprise a maleportion of a bayonet connection that interacts with a correspondingfemale portion of a bayonet connection provided within theaerosol-generating device. In such embodiments, the male and femaleportions of the bayonet connection form the article and device securingelements respectively. In those embodiments in which the resistiveheating element comprises a disc of electrically insulating material themale portion of the bayonet connection is preferably provided by thedisc of electrically insulating material.

In any of the embodiments described above, the aerosol-generatingarticle may have a substantially circular cross-sectional shape. In suchembodiments, the at least two heater electrical contacts may comprise afirst heater electrical contact spaced apart from a second heaterelectrical contact, wherein the aerosol-generating article furthercomprises an indexing indicator to indicate the rotational orientationof the aerosol-generating article. Providing an indexing indicator onthe aerosol-generating article advantageously assists the consumer ininserting the aerosol-generating article into an aerosol-generatingdevice in the correct orientation so that the at least two heaterelectrical contacts are aligned with and contact corresponding deviceelectrical contacts as may be provided inside the aerosol-generatingdevice.

For example, the aerosol-generating article may comprise a shapedportion, such as a raised portion or an indentation, which forms theindexing indicator. In such embodiments, the indexing indicator maycooperate with a correspondingly shaped portion on an aerosol-generatingdevice. For example, the aerosol-generating article may comprise agroove in an outer surface of the article which must be aligned with acorrespondingly shaped ridge on an interior surface of anaerosol-generating device to allow insertion of the article into thedevice.

Additionally, or alternatively, the indexing indicator may comprise oneor more indicia provided on an outer surface of the aerosol-generatingarticle, which must be aligned with a corresponding indicia provided onan aerosol-generating device. In such embodiments, at least one indiciais preferably provided at the downstream end of the aerosol-generatingarticle so that it remains visible to the consumer when theaerosol-generating article has been inserted into an aerosol-generatingdevice.

In alternative embodiments, the aerosol-generating article may have asubstantially circular cross-sectional shape centred on a longitudinalaxis of the aerosol-generating article, wherein the at least two heaterelectrical contacts comprise a first heater electrical contact having anannular shape centred on the longitudinal axis of the aerosol-generatingarticle and a second heater electrical contact having a circular or anannular shape centred on the longitudinal axis of the aerosol-generatingarticle. An outer diameter of the second heater electrical contact issmaller than an inner diameter of the first heater electrical contact,and the second heater electrical contact is positioned within the firstheater electrical contact.

Advantageously, forming a first of the heater electrical contacts as anannular contact with the second heater contact coaxially positionedwithin the first heater electrical contact and on the longitudinal axisof the aerosol-generating article provides a heater electrical contactconfiguration that is independent of the rotational orientation of theaerosol-generating article. Therefore, in such embodiments, an indexingindicator may not be required as the correct contact between the heaterelectrical contacts and device electrical contacts in anaerosol-generating device may be achieved with any rotationalorientation of the article with respect to the device.

In any of the embodiments described above, the aerosol-generatingarticle may further comprise an article data storage device for storingdata indicative of the type of aerosol-generating article. Additionally,or alternatively, the article data storage device may store datarelating to a heating profile for the aerosol-generating article.

In those embodiments in which the aerosol-generating article comprisesan article data storage device, the aerosol-generating articlepreferably further comprises one or more article data electricalcontacts for connecting to one or more device data electrical contactson an aerosol-generating device.

At least one of the article data storage device and the article dataelectrical contacts may be configured so that the article data storagedevice can be accessed only in a read-only mode.

For example, the article data storage device may communicate the type ofaerosol-generating article to an aerosol-generating device via thearticle data electrical contacts and device data electrical contacts sothat the aerosol-generating device can select the appropriate heatingprofile from one or more heating profiles stored within a device datastorage device. Alternatively, the article data storage device maycommunicate an appropriate heating profile to an aerosol-generatingdevice via the article data electrical contacts and device dataelectrical contacts.

Alternatively, at least one of the article data storage device and thearticle data electrical contacts may be configured so that the articledata storage device can be accessed in a read-write mode. For example,an aerosol-generating device may read at least one of the type ofaerosol-generating article and an appropriate heating profile from thearticle data storage device, as described above. Additionally, oralternatively, an aerosol-generating device may write data to thearticle data storage device. For example, an aerosol-generating devicemay write data to the article data storage device to indicate that theaerosol-generating article has been smoked. If the smokedaerosol-generating article is then re-inserted into anaerosol-generating device, the aerosol-generating device may read thedata from the article data storage device indicative of theaerosol-generating article having been smoked and therefore prevent thearticle being smoked again.

In those embodiments in which the aerosol-generating article comprisesan article data storage device, the article data storage device ispreferably provided on or otherwise formed integrally with the resistiveheating element. For example, in those embodiments in which theresistive heating element comprises a disc of electrically insultingmaterial, the article data storage device is preferably provided on orwithin the disc of electrically insulating material. Similarly, in thoseembodiments in which the aerosol-generating article comprises one ormore article data electrical contacts, the article data electricalcontacts are preferably provided on the upstream face of the disc ofelectrically insulating material.

In any of the embodiments described above, the tobacco plug may compriseat least one an aerosol former, that is, a substance which generates anaerosol upon heating. The aerosol former may be, for instance, a polyolaerosol former or a non-polyol aerosol former. It may be a solid orliquid at room temperature. Suitable polyols include sorbitol, glycerol,and glycols like propylene glycol or triethylene glycol. Suitablenon-polyols include monohydric alcohols, such as menthol, high boilingpoint hydrocarbons, acids such as lactic acid, and esters such asdiacetin, triacetin, triethyl citrate or isopropyl myristate. Aliphaticcarboxylic acid esters such as methyl stearate, dimethyl dodecanedioateand dimethyl tetradecanedioate can also be used as aerosol formers. Acombination of aerosol formers may be used, in equal or differingproportions. Polyethylene glycol and glycerol may be particularlypreferred, whilst triacetin is more difficult to stabilise and may alsoneed to be encapsulated in order to prevent its migration within thearticle. The at least one aerosol-forming substrate may include one ormore flavouring agents, such as cocoa, liquorice, organic acids, ormenthol.

The tobacco plug may comprise one or more of: powder, granules, pellets,shreds, spaghettis, strips or sheets containing one or more of: tobaccoleaf, fragments of tobacco ribs, reconstituted tobacco, homogenisedtobacco, extruded tobacco and expanded tobacco. Optionally, the tobaccoplug may contain additional tobacco or non-tobacco volatile flavourcompounds, to be released upon heating of the tobacco plug. Optionally,the tobacco plug may also contain capsules that, for example, includethe additional tobacco or non-tobacco volatile flavour compounds. Suchcapsules may melt during heating of the tobacco plug. Alternatively, orin addition, such capsules may be crushed prior to, during, or afterheating of the tobacco plug.

Where the tobacco plug comprises homogenised tobacco material, thehomogenised tobacco material may be formed by agglomerating particulatetobacco. The homogenised tobacco material may be in the form of a sheet.The homogenised tobacco material may have an aerosol-former content ofgreater than 5 percent on a dry weight basis. The homogenised tobaccomaterial may alternatively have an aerosol former content of between 5percent and 30 percent by weight on a dry weight basis. Sheets ofhomogenised tobacco material may be formed by agglomerating particulatetobacco obtained by grinding or otherwise comminuting one or both oftobacco leaf lamina and tobacco leaf stems; alternatively, or inaddition, sheets of homogenised tobacco material may comprise one ormore of tobacco dust, tobacco fines and other particulate tobaccoby-products formed during, for example, the treating, handling andshipping of tobacco. Sheets of homogenised tobacco material may compriseone or more intrinsic binders, that is tobacco endogenous binders, oneor more extrinsic binders, that is tobacco exogenous binders, or acombination thereof to help agglomerate the particulate tobacco.Alternatively, or in addition, sheets of homogenised tobacco materialmay comprise other additives including, but not limited to, tobacco andnon-tobacco fibres, aerosol-formers, humectants, plasticisers,flavourants, fillers, aqueous and non-aqueous solvents and combinationsthereof. Sheets of homogenised tobacco material are preferably formed bya casting process of the type generally comprising casting a slurrycomprising particulate tobacco and one or more binders onto a conveyorbelt or other support surface, drying the cast slurry to form a sheet ofhomogenised tobacco material and removing the sheet of homogenisedtobacco material from the support surface.

The aerosol-generating article may have a total length of betweenapproximately 30 millimetres and 100 millimetres. The aerosol-generatingarticle may have an external diameter of between approximately 5millimetres and approximately 13 millimetres.

The mouthpiece may be located at the downstream end of theaerosol-generating article. The mouthpiece may be a cellulose acetatefilter plug. The mouthpiece is preferably approximately 7 millimetres inlength, but can have a length of between approximately 5 millimetres toapproximately 10 millimetres.

The tobacco plug may have a length of approximately 10 millimetres.However it is most preferable for the tobacco plug to have a length of12 millimetres.

The diameter of the tobacco plug may be between approximately 5millimetres and approximately 12 millimetres.

Preferably, the aerosol-generating article is a cigarette. In apreferred embodiment, the aerosol-generating article has a total lengthbetween 40 millimetres and 50 millimetres.

Preferably, the aerosol-generating article has a total length ofapproximately 45 millimetres. It is also preferable for theaerosol-generating article to have an external diameter of approximately7.2 millimetres.

The present invention also extends to electrically heatedaerosol-generating systems comprising the aerosol-generating articledescribed above. Therefore, according to a second aspect of the presentinvention there is provided an electrically heated aerosol-generatingsystem comprising an aerosol-generating article according to the firstaspect of the present invention, in accordance with any of theembodiments described above, and an aerosol-generating device. Theaerosol-generating device comprises a tubular housing comprising acavity for receiving at least an upstream portion of theaerosol-generating article. The aerosol-generating device also comprisesa supply of electrical energy within the tubular housing, and at leasttwo device electrical contacts connected to the supply of electricalenergy. The at least two device electrical contacts are positioned at anupstream end of the cavity and configured to contact the at least twoheater electrical contacts when the aerosol-generating article isinserted into the cavity to transfer electrical energy from the supplyof electrical energy to the resistive heating element.

In some embodiments, the aerosol-generating article and the cavity mayboth have a substantially circular cross-sectional shape. In suchembodiments, the at least two heater electrical contacts may comprise afirst heater electrical contact spaced apart from a second heaterelectrical contact, and the at least two device electrical contacts maycomprise a first device electrical contact spaced apart from a seconddevice electrical contact. The aerosol-generating article and theaerosol-generating device may each comprise an indexing indicator toindicate the rotational orientation of the aerosol-generating articlewith respect to the aerosol-generating device when theaerosol-generating article is received within the cavity. As describedabove, providing an indexing indicator on each of the aerosol-generatingarticle and the aerosol-generating device advantageously assists theconsumer in inserting the aerosol-generating article into theaerosol-generating device in the correct orientation so that the atleast two heater electrical contacts are aligned with and contact thecorresponding device electrical contacts.

In any of the embodiments described above in which theaerosol-generating article comprises an article securing element, theaerosol-generating device preferably comprises a device securing elementconfigure to interact with the article securing element to releasablyretain the aerosol-generating article within the aerosol-generatingdevice. By releasably retaining the aerosol-generating article withinthe aerosol-generating device the article securing element and thedevice securing element can advantageously ensure that a reliableelectrical contact is maintained between the heater electrical contactsand the corresponding device electrical contacts during heating of theaerosol-generating article.

The article securing element and the device securing element arepreferably configured so that forces exerted on the aerosol-generatingarticle during normal use of the electrically heated aerosol-generatingsystem are insufficient to break the electrical contact between theheater electrical contacts and the device electrical contacts, whilealso being configured so that a consumer can easily remove theaerosol-generating article, including the resistive heating element,from the aerosol-generating device. For example, the resistive heaterelement may comprise a magnetised material provided at an upstream endof the resistive heater element, wherein the magnetised materialinteracts with a magnetised material or a non-magnetised butferromagnetic material provided within the aerosol-generating device.Alternatively, the aerosol-generating device may comprise a magnetisedmaterial configured to interact with a magnetised material or anon-magnetised but ferromagnetic material provided at an upstream end ofthe resistive heater element.

In a preferred embodiment, at least one of the heater electricalcontacts comprises a magnetised material, wherein the at least oneheater electrical contact comprising a magnetised material ismagnetically attracted to the corresponding at least one deviceelectrical contact to releasably retain the heater electrical contactsin electrical contact with the corresponding device electrical contactswhen the aerosol-generating article is inserted into theaerosol-generating device. In such embodiments, the article securingelement comprises the at least one heater electrical contact comprisinga magnetised material and the device securing element comprises the oneor more corresponding device electrical contacts. The one or more deviceelectrical contacts corresponding to the at least one heater electricalcontact comprising a magnetised material may also comprise a magnetisedmaterial. Alternatively, the one or more device electrical contactscorresponding to the at least one heater electrical contact comprising amagnetised material may comprise a non-magnetised but ferromagneticmaterial.

In an alternative embodiment, at least one of the device electricalcontacts comprises a magnetised material, wherein the at least onedevice electrical contact comprising a magnetised material ismagnetically attracted to the corresponding at least one heaterelectrical contact to releasably retain the heater electrical contactsin electrical contact with the corresponding device electrical contactswhen the aerosol-generating article is inserted into theaerosol-generating device. In such embodiments, the device securingelement comprises the at least one device electrical contact comprisinga magnetised material and the article securing element comprises the oneor more corresponding heater electrical contacts. The one or more heaterelectrical contacts corresponding to the at least one device electricalcontact comprising a magnetised material may also comprise a magnetisedmaterial. Alternatively, the one or more heater electrical contactscorresponding to the at least one device electrical contact comprising amagnetised material may comprise a non-magnetised but ferromagneticmaterial.

In further alternative embodiments, the article and device securingelements may interact mechanically to retain the aerosol-generatingarticle within the aerosol-generating device. For example, the cavityinto which the aerosol-generating article is received may be tapered,the tapered cavity providing an interference fit between the taperedsurface of the cavity and the outer surface of the aerosol-generatingarticle. In such embodiments, the cavity forms the device securingelement and the outer surface of the aerosol-generating article formsthe article securing element. Alternatively, a different mechanicalinteraction may be provided between the aerosol-generating article andthe aerosol-generating device. For example, the aerosol-generatingarticle may comprise a male portion of a bayonet connection thatinteracts with a corresponding female portion of a bayonet connectionprovided within the aerosol-generating device. In such embodiments, themale and female portions of the bayonet connection form the article anddevice securing elements respectively. In those embodiments in which theresistive heating element comprises a disc of electrically insulatingmaterial the male portion of the bayonet connection is preferablyprovided by the disc of electrically insulating material.

For example, the aerosol-generating article may comprise a shapedportion, such as a raised portion or an indentation, which forms anindexing indicator on the aerosol-generating article that cooperateswith a correspondingly shaped indexing indicator on theaerosol-generating device. For example, the aerosol-generating articlemay comprise a groove in an outer surface of the article which must bealigned with a correspondingly shaped ridge on the interior surface ofthe cavity to allow insertion of the article into the cavity

Alternatively, the at least two device electrical contacts may comprisea first device electrical contact spaced apart from a second deviceelectrical contact, wherein the aerosol-generating article has asubstantially circular cross-sectional shape centred on a longitudinalaxis of the aerosol-generating article, and wherein the at least twoheater electrical contacts comprise a first heater electrical contacthaving an annular shape centred on the longitudinal axis of theaerosol-generating article and a second heater electrical contact havinga circular or an annular shape centred on the longitudinal axis of theaerosol-generating article. The outer diameter of the second heaterelectrical contact is smaller than an inner diameter of the first heaterelectrical contact, and the second heater electrical contact ispositioned within the first heater electrical contact.

As described above, forming a first of the heater electrical contacts asan annular contact with the second heater contact coaxially positionedwithin the first heater electrical contact and on the longitudinal axisof the aerosol-generating article advantageously provides a heaterelectrical contact configuration that is independent of the rotationalorientation of the aerosol-generating article. Therefore, in suchembodiments, an indexing indicator may not be required as the correctcontact between the heater electrical contacts and the device electricalcontacts in the aerosol-generating device may be achieved with anyrotational orientation of the article with respect to the device,providing one of the device electrical contacts is centred on alongitudinal axis of the cavity and the spacing between the first andsecond device electrical contacts is the same as the spacing between thefirst and second heater electrical contacts. In some embodiments, thefirst and second device electrical contacts may have the sameconfiguration as the heater electrical contacts. That is, the firstdevice electrical contact may be an annular electrical contactsurrounding the second device electrical contact.

In alternative embodiments, the first device electrical contact may bean annular electrical contact surrounding the second device electricalcontact, both centred on the longitudinal axis of the cavity, and thefirst and second heater electrical contacts may have any configuration,providing one of the heater electrical contacts is centred on thelongitudinal axis of the aerosol-generating article and the spacingbetween the first and second heater electrical contacts is the same asthe spacing between the first and second device electrical contacts.Such a configuration still permits insertion of the aerosol-generatingarticle into the aerosol-generating device with any rotationalorientation.

In any of the embodiments described above in which theaerosol-generating article comprises an article data storage device andone or more article data electrical contacts, the aerosol-generatingdevice preferably comprises one or more device data electrical contactsfor connecting to the one or more article data electrical contacts.

At least one of the article data storage device and the article dataelectrical contacts may be configured so that the article data storagedevice can be accessed only in a read-only mode. For example, theaerosol-generating device may comprise a device data storage devicestoring one or more heating profiles, wherein the article data storagedevice communicates the type of aerosol-generating article to theaerosol-generating device via the article data electrical contacts andthe device data electrical contacts so that the aerosol-generatingdevice can select the appropriate heating profile from the one or moreheating profiles stored within the device data storage device.Alternatively, the article data storage device may communicate anappropriate heating profile to the aerosol-generating device via thearticle data electrical contacts and the device data electricalcontacts.

Alternatively, at least one of the article data storage device and thearticle data electrical contacts may be configured so that the articledata storage device can be accessed in a read-write mode. For example,the aerosol-generating device may read at least one of the type ofaerosol-generating article and an appropriate heating profile from thearticle data storage device, as described above. Additionally, oralternatively, the aerosol-generating device may write data to thearticle data storage device. For example, the aerosol-generating devicemay write data to the article data storage device to indicate that theaerosol-generating article has been smoked. If the smokedaerosol-generating article is then re-inserted into anaerosol-generating device, the aerosol-generating device may read thedata from the article data storage device indicative of theaerosol-generating article having been smoked and therefore prevent thearticle being smoked again.

In those embodiments in which the aerosol-generating device comprises adevice data storage device, the device data storage device may store oneor more heating profiles, as described above. Additionally, oralternatively, the device data storage device may store usage data, suchas the number of article smokes, the types of articles smoked, thefrequency of smoking, and such like.

The supply of electrical energy may be a DC voltage source. In preferredembodiments, the supply of electrical energy is a battery. For example,the supply of electrical energy may be a nickel-metal hydride battery, anickel cadmium battery, or a lithium based battery, for example alithium-cobalt, a lithium-iron-phosphate or a lithium-polymer battery.The supply of electrical energy may alternatively be another form ofcharge storage device such as a capacitor. The supply of electricalenergy may require recharging and may have a capacity that allows forthe storage of enough energy for use of the aerosol-generating devicewith one or more aerosol-generating articles.

In any of the embodiments described above, the tubular housingpreferably comprises one or more airflow inlets to allow air to flowinto the electrically heated aerosol-generating system when a consumerdraws on the aerosol-generating article during use. Preferably, the oneor more airflow inlets are positioned adjacent the upstream end of theaerosol-generating article when the aerosol-generating article is fullyinserted into the aerosol-generating device.

The aerosol-generating device may further comprise a sensor to detectair flow indicative of a consumer taking a puff. The air flow sensor maybe an electro-mechanical device. Alternatively, the air flow sensor maybe any of: a mechanical device, an optical device, an opto-mechanicaldevice and a micro electro-mechanical systems (MEMS) based sensor.Alternatively, the aerosol-generating device may comprise a manuallyoperable switch for a consumer to initiate a puff.

Additionally, or alternatively, the aerosol-generating device mayfurther comprise a temperature sensor. The temperature sensor may detectthe temperature of the resistive heating element or the temperature ofthe aerosol-generating article. The temperature sensor may be athermistor. Alternatively, the temperature sensor may comprise a circuitconfigured to measure the resistivity of the resistive heating elementand derive a temperature of the resistive heating element by comparingthe measured resistivity to a calibrated curve of resistivity againsttemperature.

Preferably, the aerosol-generating device comprises an indicator forindicating when the resistive heating element is activated. Theindicator may comprise a light, activated when the heating element isactivated. Additionally, or alternatively, the aerosol-generating devicemay comprise an indicator for indicating when the heater electricalcontacts are in correct contact with the device electrical contacts. Inthose embodiments in which the aerosol-generating device comprisesindicators for indicating when the resistive heating element isactivated and when the heater electrical contacts are in correct contactwith the device electrical contacts the indicators may be differentindicators or they may be separate indicators. For example, the devicemay comprise a single indicator comprising a light that activates onlywhen the heater electrical contacts are in correct contact with thedevice electrical contacts and when the resistive heating element isactivated.

In any of the embodiments described above, the aerosol-generating devicemay comprise an external plug or socket allowing the aerosol-generatingdevice to be connected to another electrical device. For example, theaerosol-generating device may comprise a USB plug or a USB socket toallow connection of the aerosol-generating device to another USB enableddevice. For example, the USB plug or socket may allow connection of theaerosol-generating device to a USB charging device to charge arechargeable supply of electrical energy within the aerosol-generatingdevice. In those embodiments in which the aerosol-generating devicecomprises a device data storage device, the USB plug or socket mayadditionally, or alternatively, support the transfer of data to or from,or both to and from, the aerosol-generating device. For example, thedevice may be connected to a computer to download data from the devicedata storage device, such as usage data. Additionally, or alternatively,the device may be connected to a computer to transfer data to thedevice, such as new heating profiles for new aerosol-generatingarticles, wherein the heating profiles are stored within the device datastorage device.

In those embodiments in which the device comprises a USB plug or socket,the device may further comprise a removable cover that covers the USBplug or socket when not in use. In embodiments in which the USB plug orsocket is a USB plug, the USB plug may additionally or alternatively beselectively retractable within the device.

As described above, the resistive heating element may comprise anelectrically resistive heating track provided on an elongateelectrically insulating substrate. The present invention extends tomethods of manufacturing aerosol-generating articles comprising such aresistive heating element, in accordance with any of the embodimentsdescribed above. Therefore, according to a third aspect of the presentinvention there is provided a method of manufacturing anaerosol-generating article according to the first aspect of the presentinvention in accordance with the embodiments described above, the methodcomprising providing a tobacco plug and a mouthpiece, and wrapping awrapper around at least a portion of the tobacco plug and the mouthpieceto secure the mouthpiece to a downstream end of the tobacco plug. Aresistive heating element is provided, the resistive heating elementcomprising an electrically resistive heating track on an elongateelectrically insulating substrate, and at least two heater electricalcontacts for receiving a supply of electrical energy and connected tothe electrically resistive heating track. At least a portion of theelongate electrically insulating substrate is inserted into the tobaccoplug at an upstream end of the tobacco plug, wherein an upstream portionof the resistive heating element protrudes from the upstream end of thetobacco plug, and wherein the upstream portion of the resistive heatingelement comprises the at least two heater electrical contacts forreceiving a supply of electrical energy.

Providing an electrically resistive heating track on an electricallyinsulating substrate simplifies the manufacture of theaerosol-generating article by facilitating separate manufacture of theresistive heating element, which is then inserted into the tobacco plugafter the remainder of the aerosol-generating article has beenconstructed.

To facilitate the insertion of the resistive heating element into thetobacco plug, the elongate electrically insulating substrate ispreferably shaped in the form of one of a rod, a needle, a pin, a blade,or a cone, and wherein the step of inserting at least a portion of theelongate electrically insulating substrate into the tobacco plugcomprises inserting the rod, needle, pin, blade or cone into the tobaccorod.

Additionally, or alternatively, the elongate electrically insulatingsubstrate may comprise one or more serrated edges, wherein theserrations are shaped to favour insertion of the resistive heatingelement into the tobacco plug during the step of inserting at least aportion of the elongate electrically insulating substrate into thetobacco plug, and wherein the serrations are shaped to resist removal ofthe resistive heating element from the tobacco plug. Providing suchserrated edges can advantageously prevent the resistive heating elementfrom becoming dislodged from the tobacco plug when theaerosol-generating article is removed from an aerosol-generating device.

In alternative embodiments, the elongate electrically insulatingsubstrate may have a helical shape so that the resistive heating elementcan be screwed into and out of the tobacco plug but cannot be pusheddirectly into or pulled directly out of the tobacco plug. In suchembodiments, the step of inserting at least a portion of the elongateelectrically insulating substrate into the tobacco plug comprisesscrewing at least a portion of the elongate electrically insulatingsubstrate into the tobacco plug. Utilising a helical shape can preventthe resistive heating element from becoming dislodged from the tobaccoplug when the aerosol-generating article is removed from anaerosol-generating device.

In those embodiments in which the resistive heating element isdisposable with the remainder of the aerosol-generating article, theresistive heating element is preferably constructed from low-costmaterials, such as low cost metals and metal alloys. Alternatively, inthose embodiments in which the resistive heating element is reusable, itmay be cost-effective to manufacture the resistive heating element frommore expensive materials. For example, reusable resistive heatingelements may comprise an elongate electrically insulating substrateformed from a non-conductive ceramic.

Preferably, the electrically insulating substrate is operable at aworking temperature of up to about 700 degrees Celsius, more preferablyabout 800 degrees Celsius. Additionally, or alternatively, the operatingtemperature of the resistive heating element during use may be about 250degrees Celsius, more preferably about 300 degrees Celsius.

Suitable materials for forming the electrically resistive heating trackinclude but are not limited to: semiconductors such as doped ceramics,electrically “conductive” ceramics (such as, for example, molybdenumdisilicide), carbon, graphite, metals, metal alloys and compositematerials made of a ceramic material and a metallic material. Suchcomposite materials may comprise doped or undoped ceramics. Examples ofsuitable doped ceramics include doped silicon carbides. Examples ofsuitable metals include titanium, zirconium, tantalum and metals fromthe platinum group. Examples of suitable metal alloys include stainlesssteel, nickel-, cobalt-, chromium-, aluminium- titanium- zirconium-,hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-,manganese- and iron-containing alloys, and super-alloys based on nickel,iron, cobalt, stainless steel, Timetal® and iron-manganese-aluminiumbased alloys.

In some embodiments, the electrically resistive heating track comprisesone or more stamped portions of electrically resistive material, such asstainless steel. Alternatively, the electrically resistive heating trackmay comprise a heating wire or filament, for example a Ni—Cr(Nickel-Chromium), platinum, tungsten or alloy wire.

In any of the embodiments described above, the upstream portion of theresistive heating element preferably comprises a disc of electricallyinsulating material, wherein the disc comprises an upstream face onwhich the at least two heater electrical contacts are provided and adownstream face from which the electrically insulating substrateextends. The step of inserting at least a portion of the elongateelectrically insulating substrate into the tobacco plug comprisesinserting the elongate electrically insulating substrate until thedownstream face of the disc abuts the upstream end of the tobacco plug.

Providing the resistive heating element with a disc of electricallyinsulating material at its upstream end advantageously facilitatesinsertion of the resistive heating element into the tobacco plug.Specifically, the elongate electrically insulating substrate can besized so that when the resistive heating element is inserted into thetobacco plug so that the downstream face of the disc of electricallyinsulating material abuts the upstream end of the tobacco plug theelongate electrically insulating substrate, and therefore the resistiveheating track, are correctly positioned within the tobacco plug.

Advantageously, the upstream face of the disc of electrically insulatingmaterial also provides a large surface area on which the at least twoheater electrical contacts can be provided, which facilitates themanufacture of the resistive heating element.

The disc of electrically insulating material may be formed from the sameinsulating material as the elongate electrically insulating substrate,or they may be formed from different materials. Preferably, the disc ofelectrically insulating material and the elongate electricallyinsulating substrate are formed from the same material. To simplify themanufacture of the resistive heating element, the disc of electricallyinsulating material and the elongate electrically insulating substrateare preferably integrally formed from a single piece of electricallyinsulating material. For example, the resistive heating element mayformed by moulding or otherwise casting an electrically insulatingmaterial around the electrically resistive heating track.

In any of those embodiments in which the resistive heating elementcomprises a disc of electrically insulating material, the disc and thetobacco plug preferably both have a substantially circularcross-sectional shape, wherein the diameter of the disc is substantiallythe same as the diameter of the tobacco plug. This advantageouslyfacilitates correct insertion of the resistive heating element into thetobacco plug. For example, a tubular guide may be used duringmanufacture of the aerosol-generating article to ensure that the disc ofelectrically insulating material is positioned coaxially with thetobacco plug.

The present invention also extends to methods of manufacturing tobaccoplugs for use in manufacturing aerosol-generating articles comprising aresistive heater element within a tobacco plug, in accordance with anyof the embodiments of the first aspect of the present inventiondescribed above and wherein the resistive heating element isincorporated into the tobacco plug as the tobacco plug is formed.Therefore, according to a fourth aspect of the present invention thereis provided a method of manufacturing a tobacco plug for use in anaerosol-generating article according to the first aspect of the presentinvention, the method comprising positioning a resistive heating elementon a forming belt, the resistive heating element comprising at least twoheater electrical contacts for receiving a supply of electrical energy.A tobacco slurry is deposited onto the forming belt and dried to form adried tobacco sheet comprising the resistive heating element. The driedtobacco sheet comprising the resistive heating element is formed into atobacco plug, the resistive heating element positioned within thetobacco plug and comprising an upstream portion protruding from anupstream end of the tobacco plug, wherein the upstream portion of theresistive heating element comprises the least two heater electricalcontacts for receiving a supply of electrical energy.

Forming the resistive heater element integrally with the tobacco plugcan simplify the manufacture of the aerosol-generating article byreducing the number of assembly steps.

The resistive heating element may be positioned on the forming belt andthe tobacco slurry then deposited onto the forming belt over theresistive heating element. Alternatively, the tobacco slurry may bedeposited on the forming belt and the resistive heating element thenpositioned on the forming belt on top of the tobacco slurry.

The step of forming the dried tobacco sheet into a tobacco plug maycomprise at least one of rolling and folding the dried tobacco sheet.

To accommodate the step of forming the dried tobacco sheet into atobacco plug, the resistive heating element is preferably flexible. Forexample, the resistive heating element may comprise a flexible resistivewire.

The invention will now be further described, by way of example only,with reference to the accompanying drawings in which:

FIG. 1 shows an aerosol-generating article in accordance with a firstembodiment of the present invention;

FIG. 2 shows a detailed view of the heater electrical contacts of theaerosol-generating article of FIG. 1;

FIG. 3 shows an alternative arrangement of heater electrical contactsfor use with the aerosol-generating article of FIG. 1;

FIG. 4 shows an aerosol-generative device for use with theaerosol-generating article of FIG. 1;

FIG. 5 shows the aerosol-generating article of FIG. 1 inserted into theaerosol-generating device of FIG. 4 to form an electrically heatedaerosol-generating system;

FIG. 6 illustrates a method of forming the aerosol-generating article ofFIG. 1, in accordance with the present invention; and

FIG. 7 shows an aerosol-generating article in accordance with a secondembodiment of the present invention and configured for use with theaerosol-generating device of FIG. 4.

FIG. 1 shows an aerosol-generating article 10 in accordance with a firstembodiment of the present invention, the aerosol-generating article 10comprising a tobacco plug 12, a hollow acetate tube 14, a polymericfilter 16, a mouthpiece 18 and an outer wrapper 20.

The aerosol-generating article 10 further comprises a resistive heatingelement 22 positioned within the tobacco plug 12, the resistive heatingelement comprising a disc of electrically insulating material 24 and anelongate electrically insulating substrate 26 extending from adownstream face of the disc of electrically insulating material 24. Thedisc of electrically insulating material 24 and the elongateelectrically insulating substrate 26 are formed integrally as a singlepiece from a ceramic material.

An electrically resistive heating track 28 is embedded within theelongate electrically insulating substrate 26. Provided on an upstreamface of the disc of electrically insulating material 24 are heaterelectrical contacts 30, which are connected to the electricallyresistive heating track 28 for conducting a supply of electrical energyfrom an aerosol-generating device to the electrically resistive heatingtrack 28.

FIG. 2 shows a detailed view of the heater electrical contacts 30 on theupstream face of the disc of electrically insulating material 24. Theheater electrical contacts 30 comprise a first heater electrical contact32 having an annular shape and a second heater electrical contact 34having a circular shape and positioned within the first heaterelectrical contact 32. The first and second heater electrical contacts32, 34 are centred on the longitudinal axis of the disc of electricallyinsulating material 24 so that the orientation of the first and secondheater electrical contacts 32, 34 is not dependent upon the rotationalorientation of the aerosol-generating article 10 around its longitudinalaxis.

FIG. 3 shows an alternative arrangement of heater electrical contactsfor the aerosol-generating article 10 of FIG. 1. The alternativearrangement of heater electrical contacts comprises a first heaterelectrical contact 36 spaced apart from a second heater electricalcontact 38. Depending upon the configuration of device electricalcontacts in the aerosol-generating device with which theaerosol-generating article 10 is used, it may be necessary to insert theaerosol-generating article 10 into the aerosol-generating device with aparticular rotational orientation when using the alternative heaterelectrical contact arrangement show in FIG. 3. Therefore, in suchembodiments the aerosol-generating article 10 can be provided with anindexing indicator to ensure correct rotational orientation of theaerosol-generating article 10. For example, as shown in FIG. 3, a groove40 may be provided in the disc of electrically insulating material 24,wherein the groove must be matched with a correspondingly shaped ridgeon an aerosol-generating device to allow insertion of theaerosol-generating article 10 into the aerosol-generating device.

FIG. 4 shows an aerosol-generating device 50 for use with theaerosol-generating article of FIG. 1. The device 50 includes a supply ofelectrical energy 52 in the form of a rechargeable battery. A controller54 controls the operation of the device 50, including the supply ofelectrical energy from the battery to the resistive heating element 22of an aerosol-generating article 10. The aerosol-generating device 50comprises a tubular housing 55 housing the supply of electrical energy52 and the controller 54, the tubular housing 55 defining a cavity 57for receiving the aerosol-generating article 10. A plurality of airflowinlets 59 are provided in the tubular housing 55 to allow air to flowinto the cavity 57 during use of the aerosol-generating device 50 withthe aerosol-generating article 10.

The aerosol-generating device 50 also comprises first and second deviceelectrical contacts 56, 58 that are arranged to contact the heaterelectrical contacts 30 of the aerosol-generating article 10 when thearticle is inserted into the cavity 57 to form an electrically heatedaerosol-generating system 60, as shown in FIG. 5. During operation ofthe electrically heated aerosol-generating system 60, electrical energyis supplied from the battery to the resistive heating track 28 of theresistive heating element 22 via the first and second device electricalcontacts 56, 58 and the first and second heater electrical contacts 32,34.

FIG. 6 illustrates a method of forming the aerosol-generating article 10of FIG. 1 in which the tobacco plug 12, the hollow acetate tube 14, thepolymeric filter 16, the mouthpiece 18 and the outer wrapper 20 arepre-assembled. The resistive heating element 22 is then inserted intothe tobacco plug 12 until the downstream face of the disc ofelectrically insulating material 24 abuts the upstream face of thetobacco plug 12, thus forming the aerosol-generating article 10 of FIG.1.

FIG. 7 illustrates an aerosol-generating article 100 in accordance witha second embodiment of the present invention. The aerosol-generatingarticle 100 is substantially the same as the aerosol-generating article10 shown in FIG. 1, with the exception of the resistive heating element,and like reference numerals are used to designate like parts.

The aerosol-generating article 100 comprises a resistive heating element122 comprising an electrically resistive wire 126 positioned within thetobacco plug 12. The electrically resistive wire 126 may be incorporatedinto the tobacco plug 12 during the process of forming the tobacco plug12. For example, the electrically resistive wire 126 can be combinedwith a tobacco slurry on a forming belt, after which the tobacco slurryis dried to form a dried tobacco sheet comprising the electricallyresistive wire 126, the dried tobacco sheet then being formed into thetobacco plug 12.

The resistive heating element 122 also comprises heater electricalcontacts 130 provided at the upstream end of the aerosol-generatingarticle 100 and connected to the electrically resistive wire 126. Theheater electrical contacts 130 can be configured to permit use of theaerosol-generating article 100 with the aerosol-generating device 50 ofFIG. 4.

1.-15. (canceled)
 16. An aerosol-generating article, comprising: atobacco plug; a mouthpiece disposed downstream of the tobacco plug; anda resistive heating element disposed within the tobacco plug andcomprising an upstream portion protruding from an upstream end of thetobacco plug, the upstream portion of the resistive heating elementcomprising at least two heater electrical contacts configured to receivea supply of electrical energy from at least two device electricalcontacts when the aerosol-generating article comprising the resistiveheating element is inserted into an aerosol-generating device.
 17. Theaerosol-generating article according to claim 16, wherein the resistiveheating element further comprises an electrically resistive heatingtrack disposed on an elongate electrically insulating substrate, andwherein the electrically resistive heating track is electricallyconnected to the at least two heater electrical contacts.
 18. Theaerosol-generating article according to claim 17, wherein the elongateelectrically insulating substrate is shaped in the form of one of a rod,a needle, a pin, a blade, or a cone.
 19. The aerosol-generating articleaccording to claim 17, wherein an upstream portion of the resistiveheating element comprises a disc of electrically insulating material,wherein the disc comprises a downstream face abutting an upstream end ofthe tobacco plug, wherein the elongate electrically insulating substrateextends downstream from the downstream face of the disc, and wherein thedisc further comprises an upstream face on which the at least two heaterelectrical contacts are disposed.
 20. The aerosol-generating articleaccording to claim 19, wherein the disc and the tobacco plug both have asubstantially circular cross-sectional shape, and wherein a diameter ofthe disc is substantially the same as a diameter of the tobacco plug.21. The aerosol-generating article according to claim 16, furthercomprising an article securing element configured to interact with adevice securing element on the aerosol-generating device to releasablyretain the aerosol-generating article within the aerosol-generatingdevice.
 22. The aerosol-generating article according to claim 16,wherein at least one of the at least two heater electrical contactsand/or at least one of the at least two device electrical contactscomprises a magnetized material configured to releasably retain the atleast two heater electrical contacts in electrical contact withcorresponding device electrical contacts when the aerosol-generatingarticle is inserted into the aerosol-generating device.
 23. Theaerosol-generating article according to claim 16, wherein theaerosol-generating article has a substantially circular cross-sectionalshape centered on a longitudinal axis of the aerosol-generating article,wherein the at least two heater electrical contacts comprise a firstheater electrical contact having an annular shape centered on thelongitudinal axis of the aerosol-generating article and a second heaterelectrical contact having a circular or an annular shape centered on thelongitudinal axis of the aerosol-generating article, wherein an outerdiameter of the second heater electrical contact is smaller than aninner diameter of the first heater electrical contact, and wherein thesecond heater electrical contact is disposed within the first heaterelectrical contact.
 24. An electrically heated aerosol-generatingsystem, comprising: an aerosol-generating article comprising: a tobaccoplug, a mouthpiece disposed downstream of the tobacco plug, and aresistive heating element disposed within the tobacco plug andcomprising an upstream portion protruding from an upstream end of thetobacco plug, the upstream portion of the resistive heating elementcomprising at least two heater electrical contacts; and anaerosol-generating device comprising: a tubular housing comprising acavity configured to receive at least an upstream portion of theaerosol-generating article, a supply of electrical energy within thetubular housing, and at least two device electrical contacts connectedto the supply of electrical energy, wherein the at least two deviceelectrical contacts are disposed at an upstream end of the cavity andare configured to contact the at least two heater electrical contactswhen the aerosol-generating article is inserted into the cavity totransfer electrical energy from the supply of electrical energy to theresistive heating element, and wherein the at least two heaterelectrical contacts are configured to receive a supply of electricalenergy from at least two device electrical contacts when theaerosol-generating article comprising the resistive heating element isinserted into the aerosol-generating device.
 25. The electrically heatedaerosol-generating system according to claim 24, wherein the at leasttwo device electrical contacts comprise a first device electricalcontact spaced apart from a second device electrical contact, whereinthe aerosol-generating article has a substantially circularcross-sectional shape centered on a longitudinal axis of theaerosol-generating article, wherein the at least two heater electricalcontacts comprise a first heater electrical contact having an annularshape centered on the longitudinal axis of the aerosol-generatingarticle and a second heater electrical contact having a circular or anannular shape centered on the longitudinal axis of theaerosol-generating article, wherein an outer diameter of the secondheater electrical contact is smaller than an inner diameter of the firstheater electrical contact, and wherein the second heater electricalcontact is disposed within the first heater electrical contact.
 26. Amethod of manufacturing an aerosol-generating article, comprising:providing a tobacco plug and a mouthpiece; wrapping a wrapper around atleast a portion of the tobacco plug and the mouthpiece to secure themouthpiece to a downstream end of the tobacco plug; providing aresistive heating element comprising an electrically resistive heatingtrack on an elongate electrically insulating substrate, and at least twoheater electrical contacts configured to receive a supply of electricalenergy and being connected to the electrically resistive heating track;and inserting at least a portion of the elongate electrically insulatingsubstrate into the tobacco plug at an upstream end of the tobacco plug,the upstream portion of the resistive heating element protruding fromthe upstream end of the tobacco plug, wherein the upstream portion ofthe resistive heating element comprises the at least two heaterelectrical contacts configured to receive the supply of electricalenergy.
 27. The method according to claim 26, wherein the elongateelectrically insulating substrate is shaped in the form of one of a rod,a needle, a pin, a blade, or a cone, and wherein the step of insertingat least the portion of the elongate electrically insulating substrateinto the tobacco plug further comprises inserting the rod, the needle,the pin, the blade, or the cone into the tobacco rod.
 28. The methodaccording to claim 26, wherein the upstream portion of the resistiveheating element comprises a disc of electrically insulating material,wherein the disc comprises an upstream face on which the at least twoheater electrical contacts are disposed and a downstream face from whichthe electrically insulating substrate extends, and wherein the step ofinserting at least the portion of the elongate electrically insulatingsubstrate into the tobacco plug further comprises inserting the elongateelectrically insulating substrate until the downstream face of the discabuts the upstream end of the tobacco plug.
 29. The method according toclaim 28, wherein the disc and the tobacco plug both have asubstantially circular cross-sectional shape, and wherein a diameter ofthe disc is substantially the same as a diameter of the tobacco plug.30. The A method of manufacturing a tobacco plug, comprising:positioning a resistive heating element on a forming belt, the resistiveheating element comprising at least two heater electrical contactsconfigured to receive a supply of electrical energy; depositing atobacco shiny onto the forming belt; drying the tobacco slurry to form adried tobacco sheet comprising the resistive heating element; andforming the dried tobacco sheet comprising the resistive heating elementinto a tobacco plug, the resistive heating element positioned within thetobacco plug and comprising an upstream portion protruding from anupstream end of the tobacco plug, wherein the upstream portion of theresistive heating element comprises the least two heater electricalcontacts configured to receive the supply of electrical energy.